Rotational thrombectomy wire coupler

ABSTRACT

An assembly for breaking up vascular thrombus or other obstructive material including a motor housing having a motor, a motor shaft extending from the motor, a first housing positioned at a distal end of the motor shaft, a rotational thrombectomy wire and a second housing positioned at a proximal end of the wire. The first housing has a first magnet positioned therein and recessed from the distal edge of the first housing which has a first plurality of teeth. The second housing has a second magnet positioned therein and recessed from a proximal edge of the second housing which has a second plurality of teeth intermeshing with the first plurality of teeth when the wire is coupled to the motor shaft. The first and second plurality of teeth slip when a torque of the motor shaft exceeds a predetermined value.

This application claims priority from provisional application Ser. No. 61/486,425, filed May 16, 2011, and is a continuation in part of Ser. No. 13/303,339, filed Nov. 23, 2011, which claims priority from provisional application Ser. No. 61/431,169, filed Jan. 10, 2011, and is a continuation in part of Ser. No. 13/095,329, filed Apr. 27, 2011, which claims priority from provisional application Ser. No. 61/334,412, filed May 13, 2010. The entire contents of each of these applications are incorporated herein by reference.

BACKGROUND

1. Technical Field

This application relates to a rotational thrombectomy wire for clearing thrombus from native vessels and grafts.

2. Background of Related Art

There have been various attempts to break up clots and other obstructing material in grafts or native vessels. One approach is through injection of thrombolytic agents such as urokinase or streptokinase. These agents, however, are expensive, require lengthier hospital procedures and create risks of drug toxicity and bleeding complications as the clots are broken.

Other approaches to breaking up clots involve mechanical thrombectomy devices. For example, U.S. Pat. No. 5,766,191 discloses a cage or basket composed of six memory wires that expand to press against the inner lumen to conform to the size and shape of the lumen. This multiple wire device is expensive and can be traumatic to the graft, possibly causing damage, since as the basket rotates, the graft is contacted multiple times by the spinning wires. Other risks associated with the basket include the possibility of catching onto the graft itself and tearing the graft as well as catching and tearing the suture at the anastomotic site. Additionally, the basket can become filled with a clot which would then require time consuming withdrawal of the basket, cleaning the basket and reinserting it into the lumen. This device could be traumatic if used in the vessel, could denude endothelium, create vessel spasms and has the potential for basket and drive shaft fracture.

U.S. Pat. No. 6,090,118, incorporated herein by reference in its entirety, discloses a wire rotated to create a standing wave to break-up or macerate thrombus. The single wire is less traumatic than the aforedescribed basket device since it minimizes contact with the graft wall while still effectively mechanically removing thrombotic material.

U.S. Pat. No. 7,037,316 discloses another example of a rotational thrombectomy wire for breaking up clots in grafts. The thrombectomy wire has a sinuous shape at its distal end and is contained within a sheath in a substantially straight non-deployed position. When the sheath is retracted, the distal portion of the wire is exposed to enable the wire to return to its non-linear sinuous configuration. The wire is composed of two stainless steel wires wound side by side with an elastomeric tip at the distalmost end. Actuation of the motor causes rotational movement of the wire, creating a wave pattern, to macerate thrombus. Thus, it provides the additional advantages of increased reliability and consistency in creating the wave pattern since the wave pattern created by the standing wave of the '118 patent will depend more on the rotational speed and the stiffness of the wire. Additionally, the sinuous configuration enables creation of a wave pattern at a lower rotational speed.

Although the sinuous wire of the '316 patent is effective in proper clinical use to macerate thrombus in dialysis grafts, it is not best suited for use in native vessels. US patent publication no. US 2006/0106407 (now U.S. Pat. No. 7,819,887), the entire contents of which are incorporated herein by reference, discloses a thrombectomy wire better suited for use in native vessels (and can also be used for deep vein thrombosis and pulmonary embolisms).

In neurovascular thrombectomy procedures, the thrombectomy wire needs to navigate tortuous vessels. That is, the wire is inserted through the femoral artery and then must navigate small and tortuous vessels as it is advanced to the smaller cerebral arteries of the brain. Within the brain, the carotid and vertebrobasilar arteries meet to form the circle of Willis. From this circle, other arteries, e.g., the anterior cerebral artery, the middle cerebral artery and the posterior cerebral artery, arise and travel to various parts of the brain. Clots formed in these cerebral arteries can cause stroke and in certain instances death of the patient.

Due to the size and curves of the vessels en route to the cerebral arteries from the femoral artery, as well as the size and structure of cerebral arteries themselves, access is difficult. If the thrombectomy device is too large then navigation through the small vessels, which can be as small as 1 mm, would be difficult. Also, if the device is too stiff, then it can damage the vessel walls during insertion. On the other hand, if the device is too flexible, it will lack sufficient rigidity to be advanced around the vessel curves and can be caught in the vessel. Consequently, it would be advantageous to provide a thrombectomy device for breaking cerebral clots that strike the optimal balance of flexibility and stiffness, thus effectively having the insertability of a tracking guidewire while enabling high speed rotation to effectively macerate clots without damaging vessels.

SUMMARY

The present disclosure provides in one aspect an assembly for breaking up vascular thrombus or other obstructive material. The assembly comprises a motor housing having a motor contained therein, a motor shaft extending from the motor, a first housing, a rotational thrombectomy wire and a second housing. The first housing is positioned at a distal end of the motor shaft and has a first magnet positioned therein recessed from a distal edge of the first housing. The distal edge of the first housing has a first plurality of teeth. A second housing is positioned at a proximal end of the thrombectomy wire and has a second magnet positioned therein recessed from a proximal edge of the second housing. The proximal edge of the second housing has a second plurality of teeth intermeshing with the first plurality of teeth when the wire is coupled to the motor shaft. The first and second magnets provide an attractive force between the first and second housings to intermesh the first plurality of teeth and the second plurality of teeth, the first and second plurality of teeth slipping when a torque of the motor shaft exceeds a predetermined value.

The distal end of the thrombectomy wire can be non-linear in configuration. In some embodiments, the non-linear distal end of the wire can be J-shaped in configuration; in other embodiments, the non-linear distal end of the wire can be sinuous shaped.

The assembly can further include an introducer sheath having a lumen wherein the thrombectomy wire is slidable within the lumen.

The first and second housings are preferably removably coupled.

In one embodiment, the first housing includes a first gap and the second housing includes a second gap, the first magnet axially movable within the first gap as the first housing rotates and the second magnet axially movable in the second gap as the second housing rotates. A first plug can be provided to close the first gap and a second plug can be provided to close the second gap.

Preferably, the distal edge of the first housing forms a wavy pattern and the proximal edge of the second housing forms a wavy pattern.

In accordance with another aspect of the disclosure, an assembly for breaking up vascular thrombus or other obstructive material is provided comprising a motor housing having a motor contained therein, a motor shaft extending from the motor, a first housing positioned at a distal end of the motor shaft, a rotational thrombectomy wire, and a second housing positioned at a proximal end of the thrombectomy wire. The first housing has a first magnet positioned therein and the second housing has a second magnet positioned therein. The first and second magnets provide an attractive force for the first and second housings. A cover forms a clutch positioned over an end of one of the first and second housings.

In some embodiments, the first magnet flares a distal end of the first housing when inserted therein to provide frictional engagement. In some embodiments, the cover is in the form of a disc, the disc being formed of a polymeric material and forming a clutch. In some embodiments, the polymeric disc is a latex sheet of material. In some embodiments, the cover is composed of a material that wears away after a period of use.

The assembly can further include a sheath, wherein exposure of the wire from the sheath enables a distal portion of the wire to assume a non-linear configuration.

In some embodiments, operatively coupling the motor to the thrombectomy wire occurs prior to inserting the thrombectomy wire through the sheath. In other embodiments, operatively coupling the motor to the thrombectomy wire occurs subsequent to inserting the thrombectomy wire through the sheath.

In some embodiments, a vacuum can be provided to remove particles from the vessel.

The thrombectomy wire in some embodiments can be inserted into the cerebral artery. In some embodiments, the thrombectomy wire is inserted into the circle of Willis.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiment(s) of the present disclosure are described herein with reference to the drawings wherein:

FIG. 1 is a perspective view of a first embodiment of a thrombectomy apparatus of the present invention;

FIG. 1A is a perspective view of an alternate embodiment of the apparatus;

FIG. 2 is an exploded view of the proximal portion of the thrombectomy apparatus of FIG. 1;

FIG. 2A is a perspective view of one embodiment of the motor housing attachable to the thrombectomy wire;

FIG. 2B is an exploded view of the motor housing of FIG. 1 showing the components for operatively connecting the motor to the thrombectomy wire;

FIG. 2C is a side view in partial cross-section of the coupler of FIG. 2B;

FIG. 2D is a perspective view of the coupler of FIG. 2C;

FIG. 2E is a side view in partial cross section illustrating the connection of the internal components of the motor housing;

FIG. 2F is a side view showing the wire operatively connected to the motor shaft by the coupler of FIG. 2C;

FIG. 3 is a side view in partial cross-section of the apparatus of FIG. 1;

FIG. 3A is longitudinal cross-sectional view taken along line 3A-3A of FIG. 1;

FIG. 4 is a side view of the apparatus of FIG. 1 showing the rotational wire in a non-linear position corresponding to a position exposed from the introducer sheath;

FIG. 4A is an enlarged view of the distal portion of one embodiment of the thrombectomy wire having a sinuous configuration;

FIG. 4B is an enlarged view of the distal portion of an alternate embodiment of the thrombectomy wire having a J-tip configuration;

FIG. 5 is a longitudinal cross-sectional view of the distal portion of the thrombectomy wire of the apparatus of FIG. 1;

FIG. 6 is an anatomical view showing select cerebral arteries;

FIG. 7 is a front anatomical view showing select cerebral arteries, including the circle of Willis;

FIG. 8 illustrates insertion of a guide catheter through the femoral artery and into the cerebral artery over a tracking guidewire;

FIG. 9 is a view similar to FIG. 8 illustrating withdrawal of the tracking guidewire;

FIG. 9A is a perspective view illustrating attachment of the RHV to the introducer catheter;

FIG. 10 illustrates insertion of the RHV and introducer catheter through the guide catheter and into the circle of Willis;

FIG. 10A is a perspective view illustrating insertion of the introducer sheath into the RHV;

FIG. 10B is a perspective view illustrating attachment of the connector tube to the introducer sheath;

FIG. 10C is a perspective view of another introducer catheter;

FIG. 10D is a side view showing attachment of the RHV and introducer catheter of FIG. 10C;

FIG. 11 illustrates insertion of the thrombectomy wire of FIG. 1 into the RHV and through the introducer catheter, and continued advancement of the wire from the introducer catheter so the distal portion of the wire is positioned in the circle of Willis;

FIG. 12 is a side view in partial cross section similar to FIG. 2E showing an alternate embodiment of a coupler for coupling the thrombectomy wire to the motor;

FIG. 13 is a perspective view of the coupler of FIG. 12;

FIG. 14 is a cross-sectional view of the coupler of FIG. 13 shown within the motor housing coupling the motor shaft to the thrombectomy wire;

FIG. 15 is a perspective view of an alternate embodiment of the coupler for coupling the thrombectomy wire to the motor;

FIG. 16 is a front view of the housing of FIG. 15 for receiving the motor shaft; and

FIG. 17 is a cross-sectional view of the coupler of FIG. 15 shown within the motor housing coupling the motor shaft to the thrombectomy wire.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring now in detail to the drawings where like reference numerals identify similar or like components throughout the several views, FIG. 1 illustrates a first embodiment of the thrombectomy apparatus of the present invention.

The thrombectomy apparatus of FIG. 1 is designated generally by reference numeral 10. With reference to FIGS. 1 and 2, the apparatus includes a motor housing 12, a rotational thrombectomy wire 30, a rotating hemostatic valve (RHV) 40, an introducer sheath 60 and a telescoping tube or tubular connector 80. The RHV 40 is connectable to an introducer catheter 100 discussed below in conjunction with the method of use. The introducer sheath 60 is insertable into the RHV 40 to facilitate insertion of the thrombectomy wire 30 through the introducer catheter 100.

The thrombectomy apparatus or assembly 10 disclosed herein provides a rotational thrombectomy wire as a separate unit from a catheter. That is, the thrombectomy wire 30 is provided as a separate unit insertable through the RHV 40 which has a distal end 52 connected to a proximal end of the introducer catheter 100 to access the surgical site. The introducer sheath 60 aids insertion of the thrombectomy wire 30 into the RHV 40 and through the introducer catheter 100, with the walls of the introducer sheath 60 maintaining the non-linear distal end of the wire 30 in a substantially straightened (substantially linear) configuration as it enters the RHV 40.

Additionally, the thrombectomy wire 30 of the present invention can be slid within the introducer sheath 60 and introducer catheter 100 prior to connection to the motor, if desired. This can aid introduction and manipulation of the wire 30 since it is less cumbersome and of lighter weight than if the motor housing 12 was attached during manipulation of the wire. However, it is also contemplated that the wire 30 could be attached to the motor housing 12 prior to insertion through the introducer sheath 60, RHV 40 and the introducer catheter 100 and thus the wire 30 would be slidable within the introducer sheath 60 (and introducer catheter 100) with the motor housing 12 attached. Thus, the motor housing 12 can be attached to the wire at a desired time prior to or during the procedure.

Turning to the specific components of the thrombectomy apparatus 10, and with reference to FIGS. 1-4, the motor housing 12, which also forms a handle portion, has two identical housing halves 13 a, 13 b. A motor 14 is seated within recess 14 a of housing half 13 a and the opposing recess of housing half 13 b and has a motor drive shaft 15 extending therefrom. Tabs 15 b (FIG. 3) help secure the motor 14 within the housing 12. A gear reducer (not shown) could optionally be provided to reduce by way of example the rotational speed of the motor 52 from 15,000 rpm to 1500 rpm, 750 rpm, 150 rpm, etc. One or more batteries 16, such as a 3 Volt battery, is positioned in recess 17 a of housing half 13 a and the opposing recess of housing half 13 b for powering the motor 14. The battery(s) 16 can be contained within a compartment in the housing 12 accessible by removing a battery door. The motor drive shaft 15 connects to a proximal end of the thrombectomy wire 30 by various couplings, such as for example a snap fit wherein cap 31 is frictionally fit within the lumen 15 a of the motor drive shaft 15. Various other types of connections are also contemplated. A printed circuit board can also be provided within the housing 30 and is designated by reference numeral 18.

Motor housing 12 includes a distal tubular portion 22 having a tab in the form of a ring 24 which fits within a groove in the tube connector 80, best shown in FIG. 3 to connect the motor housing 12 to tube connector 80 described below.

Switch 19 extends though recess 21 in housing half 13 a and in a corresponding recess in housing half 13 b. A potentiometer (not shown) can optionally be wired to the motor to enable dialing the motor speed up or down to adjust the rotational speed of the thrombectomy wire 30 to adjust for various procedures and/or clot locations and sizes. In a preferred embodiment, the potentiometer is used as a two terminal variable resistor, i.e. a rheostat, by not connecting the third terminal. In this manner, in the initial position, the motor speed is at the desired minimum and rotation of a knob (or in alternate embodiments sliding of a knob) progressively increases the motor speed. Thus, the on/off switch 19 extending from the housing 12 is electrically connected to the motor 15 to turn on the motor 15 to activate the apparatus, i.e. rotate the wire 30.

Turning to the other components illustrated in FIGS. 2-4, rotating hemostatic valve (RHV) 40 is connectable to an introducer catheter 100 (see FIG. 9A). A conventional introducer catheter can be utilized or alternatively a specially designed catheter for use with the apparatus of the present invention. As is standard, the RHV 40 is rotatable with respect to the catheter 100 to alter the orientation of the side arm 56.

Side arm 56 extends from the tubular portion 46 and has a port 57 for introduction of fluids and/or application of vacuum as described below. Luer lock is provided at the distal end 52 of RHV 40 to connect to the introducer catheter as threads 51 a of rotation knob 51 threadingly engage proximal threads of the introducer catheter 100. Tube extension 48 fits within the lumen of the introducer catheter 100 when attached. Washers 49 a, 49 b help to provide a seal against fluid flow.

Tubular portion 46 of RHV 40 includes a lumen 55 extending therethrough to slidably receive the tubular portion 62 of the introducer sheath 60. Proximal cap 58 at proximal end 54 has internal threads 59 to threadingly attach to external proximal threads 47 for attachment of the cap 58 to the RHV 40. Further, a crush ring 43 and distal ring 44 are seated within the internal lumen 55 of the tubular portion 46. Thus, as cap 58 is tightened on RHV 40 by rotation, it compresses rings 43 and 44 against the tubular portion 62 of introducer sheath 60 extending therethrough to connect the introducer sheath 60 to the RHV 40 (see FIG. 3A). A proximal seal 45 can also be provided. Flange 46 a on the proximal end 54 of RHV 40 interacts with lip 58 a of cap 58 to allow loosening of cap 58 to release introducer sheath 60 without cap 58 detaching from RHV 40.

Side arm 56 of RHV 40 has a lumen 53 in fluid communication with lumen 55 of tubular portion 46. Fluids such as imaging dye can be injected through the arm 56, flowing through the lumens 53 and 55, i.e. through the space between the outer wall of the introducer sheath 60 and the inner wall of lumen 55 and then through the space between the thrombectomy wire 30 the inner wall of the introducer catheter 100 and, exiting a distal opening 103 (FIG. 10) in the introducer catheter 100 to flow into the vessel. This imaging dye can be used to provide an indication that fluid flow has resumed in the vessel.

The side arm 56 can also be used for vacuum to suction particles detached from the vessel by the rotational wire 30. The particles would flow into the distal opening 103 of the introducer catheter 100 and through the space between the wire 30 and the inner wall of the introducer catheter 100, then exiting through lumen 53 and port 57 into a suction tube (not shown).

It should also be appreciated that the guide catheter 150 discussed in conjunction with the method of use can also have a side arm for injection of fluid (see e.g., side arm 152 of FIG. 8).

In the alternate embodiment of FIG. 1A, the RHV 40′ does not have a side arm. In this embodiment, a guide catheter with a side arm can be used for injection and suction. Otherwise the components are identical to the components of FIG. 1 and for convenience, the corresponding components are labeled with “prime” designations e.g., rotational knob 51′, cap 58′, introducer sheath 60′, connector tube 80′ and locking cap 83′.

The tubular portion 62 of introducer sheath 60, as noted above, extends through the lumen 55 of RHV 40 and terminates either within RI-IV 40 or at a proximal portion of the lumen of the introducer catheter 100. The tubular portion 62 preferably has a stiffness greater than the stiffness of the thrombectomy wire 30 to maintain the wire 30 in a straightened position during passage of wire 30 into the RHV 40 for subsequent passage through the lumen of the introducer catheter 100 to the surgical site.

Proximal end 65 of introducer sheath 60 is attachable to connector tube 80. Preferably, the enlarged proximal end 65 has a threaded flange 67 as shown in FIG. 3A to threadingly engage the internal threads 85 on the distal cylindrical locking cap 83 at the distal end 82 of tubular connector 80. A valve can be provided within the distal end 82 of the connector tube 80 in addition or instead of a valve in a proximal end 65 of the introducer sheath 60 to seal escape of fluid to improve the vacuum through the side arm 56.

Note the tube 80 and introducer sheath 60 can alternatively be provided as one unit, attached together and positioned over the thrombectomy wire 30. However, in alternative embodiments, the wire 30 is inserted through the introducer sheath 60 and manipulated through the introducer catheter 100 to the surgical site. Once positioned, the connector tube 80 is then threadingly attached at the distal end 82 to the introducer sheath 60 as noted above and at a proximal end 84 to the motor housing 12. In this version, the connector tube 80 can be positioned over the wire 30 prior to insertion of the wire 30 through introducer sheath 60 or after insertion through the sheath 60. The wire 30 can be packaged with the sheath 60 and the tube 80 positioned thereover, or packaged apart from the sheath 60 and tube 80.

Proximal end 84 of connector tube 80 is configured for attachment to the motor housing 12 by an external ring 24 on tip 22 of motor housing 12. Ring 24 is seated within an internal groove of connector tube 80, as shown in FIG. 3, to provide a snap fit. Other types of attachment are also contemplated. The proximal end of the wire 30 is attached to the drive shaft 15 of the motor 14. In one embodiment, end cap 31 of wire 30 is snap fit within opening 15 a in motor shaft 15. Other ways to attach the wire 30 and motor shaft 15 are also contemplated such as a bayonet mount for example.

As can be appreciated, by having a detachable motor housing 12, different handles with different motor speeds and/or different batteries can be utilized by attachment to the wire 30. This can even be achieved during the same surgical procedure.

In some embodiments, the housing can be detached, sterilized and reused after recharging of the battery or replacing the battery.

In some embodiments, as an alternative to direct connection to the motor shaft, the proximal end of wire 30, after insertion to the surgical site or prior to insertion, can be attached at a proximal end to a coupler tube which is connected to a gear reducer. The connection of the motor and thrombectomy wire can be a friction fit, a magnetic coupling or a twist connect, e.g. a bayonet connection, by way of example, such as that shown in co-pending patent application Ser. No. 13/095,329, filed Apr. 27, 2011, the entire contents of which are incorporated herein by reference.

FIGS. 2A-2F show an alternative mechanism for operatively connecting the thrombectomy wire and motor. Motor housing 210 is composed of two housing halves 212 a, 212 b which form the handle of the apparatus. Seated within the recess 213 in motor housing 210 is motor 214 electrically connected to two batteries 216. Switch 218 extends through opening 220 in motor housing 210 for access by the user. Attached to motor shaft 222, which extends distally from motor 214, is magnetic coupler 230 for magnetic coupling of the thrombectomy wire to the motor housing 210. Electrical wire 226 electrically connects switch 218 to post 214 a of motor 214. Wire 229 connects the switch 218 to the positive terminal of battery 216 and wire 228 connects the negative terminal of battery 216 to motor post 214 b.

The magnetic coupler includes a tube or housing 230, preferably made of PVC, although other materials are also contemplated. Tube 230 has a proximal portion 234 which receives motor shaft 222 and a distal portion 236. A first magnet 242 is positioned in the distal portion 236 of the tube 230, and due to its transverse dimension being larger than the transverse dimension of tube 230, forces the tube 230 to flare outwardly into flared portion 233, thereby providing a tight frictional fit. A disc 240, which can be made of a polymeric or of other material, but is preferably in the form of a Latex sheet, is provided over the distal edge 238 of tube 230 to maintain the first magnet 242 within the tube 230. The disc 240 functions as a clutch for torque transfer from the motor 214 to the thrombectomy wire 30. The motor shaft 222, extending distally from motor 214, extends into the proximal end of the tube 226 and is frictionally engaged thereto.

A second magnet is contained in housing 246 which is attached to the proximal end of the thrombectomy wire 30 by gluing, overmolding, or other attachment methods. When desired to attach the thrombectomy wire 30 to the motor housing 210, the thrombectomy wire 30 is inserted into the reduced diameter portion 217 of motor housing 214 until the magnetic attraction between the second magnet and first magnet 242 maintains a magnetic connection. In this manner, when motor 214 is actuated by switch 218, motor shaft 222 rotates to thereby rotate magnetically coupled thrombectomy wire 30. Note the torque is transferred to the wire 30 due to the disc 240 functioning as a clutch.

As noted above, the disc 240 can be in the form of a polymeric sheet. The sheet can be designed to wear off after a period of time, thus wearing away the clutch, resulting in the loss of the ability to transfer torque. In this way, over-use of the apparatus can be prevented, and the apparatus can advantageously be designed for one time use in a single procedure.

An alternative embodiment for coupling the motor to the thrombectomy wire is illustrated in FIGS. 12-14. In this embodiment, housing 330 has a proximal portion 334 which frictionally receives the motor shaft 222 and a distal portion 336. The distalmost edge 338 is in a wavy pattern forming a toothed design. A first magnet 340 is positioned in the distal portion 336, recessed from the distalmost edge 338.

A second housing 350 is attached to the proximal end of the thrombectomy wire 30. The second housing 350 has a distal portion 352 to frictionally receive the wire 30 and a proximal portion 354. The proximalmost edge 358 is in a wavy pattern forming a toothed design configured to mate with the toothed design at the distalmost edge 338 of housing 330. A second magnet 360 is positioned in the proximal portion 354, recessed distally from the proximal most edge 358. In this manner, first and second magnets 340, 360 do not come into contact but provide an attractive coupling force to attach the wire 30 and motor shaft 222 of motor 214.

The first plurality of teeth 337 of first housing 330 intermesh with the second plurality of teeth 357 of the second housing 350 so that upon rotation of the motor shaft 222, the coupled housings 330, 350 rotate. Due to the interaction of the teeth 337 of housing 330 with the teeth 357 of housing 350, rotation of housing 330 causes housing 350 to rotate which thereby rotates the wire 30 attached to housing 350. These housings 330, 350 operate as a clutch mechanism. That is, if during use, the torque of the motor shaft 222 exceeds a preset value, indicating for example that the wire is caught on material in the vessel, the teeth 337, 357 of the housings 330, 350, slip such that housing 330 rotation no longer rotates housing 350. Due to the spacing of magnets 340, 360 from each other, as a result of their mounting within the recess or pockets of the respective housings 330, 350, the force at which the housings (clutch) slip is entirely dependent on the interaction of the teeth. That is, this coupling design forms a clutch which when the torque of the motor shaft exceeds a predetermined value, the teeth slip so the teeth are no longer operably intermeshed. Thus, the torsional load at which the coupling slips depends on the friction between the teeth, thereby relying solely on the coefficient of friction of the housing materials and the angle/geometry of the teeth. Slippage occurs when torsional force is greater than frictional force and the magnetic force holding the housings together. If the magnets were in direct contact, the frictional engagement of the magnets in addition to the interaction of the teeth would affect the slippage point. By relying solely on the teeth, the design is simplified. The press-fit of the magnets into the recessed pockets also facilitates manufacture.

In the alternate embodiment of FIGS. 15 and 16, the housings 430, 450, are similar to housings 330, 350 and have distalmost and proximal most edges 438, 458, respectively, which are in a wavy pattern forming teeth 437, 457, which intermesh to rotate the second housing 450 as the first housing 430 is rotated by the rotating motor shaft 222. However, in this embodiment, spherical magnets are provided within a gap in the housings 430, 450 to allow movement, e.g., rolling, of the magnets.

More specifically, housing 430 has a proximal portion 434 which receives the motor shaft 222 and a distal portion 436. The distalmost edge 438 is in a wavy pattern forming a toothed design. A first substantially spherical magnet 440 is positioned in the distal portion 436 in an internal cavity 433, recessed proximally from the distalmost edge 438. The internal cavity 433 forms a gap 435 proximal of magnet 440. A plug 439 is press fit in a proximal opening of the cavity 433 to secure the magnet 440 within the cavity 433. The motor shaft 222 can be mounted in a proximal opening in plug 439 such as by an interference fit. The magnet 440 can move within the gap 435. In this manner, as the housing 430 rotates, the magnet 440 does not rotate with the housing 430 and can float or roll within the gap 435.

A second housing 450 is attached to the proximal end of the thrombectomy wire 30. The second housing 450 has a distal portion 454 to frictionally receive the wire 30 and a proximal portion 452. The proximal most edge 458 is in a wavy pattern forming a toothed design configured to mate with the toothed design at the distalmost edge 438 of housing 430. A second substantially spherical magnet 460 is positioned in the proximal portion 452, recessed distally from the proximal most edge 458. The housing 450 has an internal cavity 453 forming a gap 455 distal of magnet 460. A plug 459 is press fit in a proximal opening of the cavity 453 to secure the magnet 460 within the cavity 453. The thrombectomy wire 30 can be mounted in a distal opening of plug 459 such as by an interference fit. The magnet 460 can move within the gap 455. In this manner, as the housing 450 rotates, the magnet 460 does not rotate with the housing and can float or roll within the gap 455. Note as with the embodiment of FIGS. 13 and 14, the first and second magnets 440, 460 do not come into contact but provide an attractive coupling force to attach the wire 30 and motor 214. The placement of the magnets in recessed pockets has the advantages described above.

The teeth 437, 457, of the respective housings 430, 450 intermesh so that upon rotation of the motor shaft 222, the attached housing 430 rotates. Due to the interaction of the teeth 437 of housing 430 with the teeth 457 of housing 450, rotation of housing 430 causes housing 450 to rotate which thereby rotates the wire 30 attached to housing 450. During such rotation, magnets 440, 460 can move, e.g., float or roll, within the gaps 433, 453 of housings 430, 450, respectively. The gaps can be sufficiently large relative to the magnets to enable the magnets to freely float therein, i.e., not only move axially but move in three dimensions. These housings 430, 450, as in the embodiment of FIGS. 13 and 14, operate as a clutch mechanism. If during use, the torque of the motor shaft exceeds a preset value, indicating that the wire is caught on a vessel, the teeth 437, 457 of the housings 430, 450, respectively, slip such that housing 430 rotation no longer rotates housing 450. Due to the spacing of magnets 440, 460 from each other, as a result of their mounting within recess of the respective housing 430, 450, the force at which the housings (clutch) slip is entirely dependent on the interaction of the teeth 437, 457. That is, as in the embodiment of FIGS. 13 and 14, this coupling design forms a clutch which when the torque of the motor shaft exceeds a predetermined value, it causes the teeth 437, 457 to slip so the teeth are no longer operably intermeshed. Thus, the torsional load at which the coupling slips depends on the friction between the teeth, thereby relying solely on the coefficient of friction of the housing materials and the angle/geometry of the teeth. Slippage occurs when torsional force is greater than frictional force and the magnetic force holding the housings together. If the magnets were in direct contact, the frictional engagement of the magnets in addition to the interaction of the teeth would affect the slippage point. By relying solely on the teeth, the design is simplified. The press-fit of the magnets into the recessed pockets also facilitates manufacture.

Note the step of operatively coupling the thrombectomy wire to the motor housing 210 using any of the foregoing coupling embodiments can occur prior to the step of inserting the thrombectomy wire through the introducer sheath and catheter. Alternatively, the step of operatively coupling the thrombectomy wire to the motor housing 210 using any of the foregoing embodiments can occur subsequent to the step of inserting the thrombectomy wire through the introducer sheath and catheter.

FIG. 5 illustrates the thrombectomy wire 30 of the present invention. The wire 30 has a distal coiled tip 91. In preferred embodiments, the distal coiled tip (and underlying cable) is angled with respect to the longitudinal axis. FIG. 4A shows the wire of FIG. 5 forming a sinuous shape. In FIG. 4B, an alternative embodiment of the wire is illustrated, wherein the wire 130 forms a J-tip which creates a standing wave upon rotation. In the J-tip configuration, due to the angle, when the wire is rotated by the motor at sufficient speed at least one vibrational node is formed. Details of this creation of a standing wave are described in U.S. Pat. No. 6,090,118, the entire contents of which are incorporated herein by reference.

In the embodiment of FIG. 4A, the wire 30 forms a substantially sinuous shape, resembling a sine curve. More specifically, wire 30 of FIG. 4A has a substantially linear portion extending through most of its length, from a proximal region, through an intermediate region, to distal region 36. At the distal region 36, wire 30 has a sinuous shape in that as shown it has a first arcuate region 33 facing a first direction (upwardly as viewed in the orientation of FIG. 4A) and a second arcuate region 35, spaced longitudinally from the first arcuate region 33, facing a second opposite direction (downwardly as viewed in the orientation of FIG. 4A). These arcuate regions 33, 35 form “peaks” to contact vascular structure as the wire 30 rotates. This angled (non-linear) distal portion includes a coiled portion with a covering material to block the interstices of the coil as discussed below. Note in a preferred embodiment, the amplitude of the proximal wave (at region 33) is smaller than the amplitude of the distal wave (at region 35), facilitating movement in and out of the catheter.

When the wire 30 is fully retracted within the introducer catheter 100 (as in FIG. 3), the curved regions of the wire 30 are compressed so the distal region 36 is contained in a substantially straight or linear non-deployed configuration. When the introducer catheter 100 is retracted by proximal axial movement (see the arrow of FIG. 4), or the wire is advanced with respect to the introducer catheter 100 or the wire 30 and catheter 100 are both moved in the respective distal and proximal directions, the distal region 36 of the wire 30 is exposed to enable the wire 30 to return to its non-linear substantially sinuous configuration shown in FIG. 4A (and FIG. 4) for rotation about its longitudinal axis within the lumen of the vessel.

Thus, as can be appreciated, the wire 30 is advanced within the introducer catheter 100 which is attached at its proximal end to the distal end of the RI-IV 40. When at the desired site, the wire 30 and introducer catheter are relatively moved to expose the wire 30 to assume its non-linear shape for motorized rotational movement to break up thrombotic material on the vessel wall. If a J-tip wire, such as wire 130, is utilized, the wire 130 can be rotated within the introducer catheter to re-orient the wire 130.

The flexible tubular portion 62 of the introducer sheath 60 can optionally contain one or more braided wires embedded in the wall to increase the stiffness. Such braided wires would preferably extend the length of the sheath.

In an embodiment of the coiled tip being composed of shape memory material, the memorized configuration is sinuous or s-shaped as in FIG. 4A. In the state within the introducer catheter 100, the wire is in a substantially linear configuration. This state is used for delivering the wire to the surgical site. When the wire is exposed to warmer body temperature, the tip transforms to its austenitic state, assuming the s-shaped memorized configuration. Alternatively, the coiled tip of the wire can be compressed within the wall of the introducer catheter and when released, assumes its shape memorized non-linear shape. The coiled tip can alternatively be a radiopaque coil/polymer pre-shaped to an “S”.

Details of the wire 30 will now be described with reference to FIG. 5. These details are the same for wire 130, the only difference being that instead of the distal coiled tip being sinuous shaped in the deployed position, the distal tip is in J-configuration. Note it is also contemplated that in an alternate embodiment the distal tip can be substantially straight (substantially linear) in both the covered and deployed (exposed) position. For convenience, details will be discussed with reference to wire 30. Wire 30 has a core 32 having a proximal portion 34 (see FIG. 2) and a distal portion 37. Transition region 38 of core 32 is tapered distally so that the diameter of the distal portion 37 of core 32 is less than the diameter of the proximal portion 34. A uniform diameter portion 37 a extends distal of tapered portion 37. The taper can be formed by removing a coating, such as a PTFE coating, placed over the core 32 and a grinding of the core 32. In one embodiment, the core 32 is a solid material made of a nickel titanium alloy, although other materials are also contemplated. The core 32 can also be formed from a hypotube with a tapered body attached, e.g. welded, to the distal end of the hypotube.

The core 32 is connected to a cable 90. The cable 90 can be formed of a plurality of wires twisted together such as a 1×19 wire for example. The twisted wires can be surrounded by additional wires or a sheath. The core 32 is tapered to accommodate connection to cable 90. Hypotube 92 is placed over the distalmost end of the core 32 (the uniform diameter portion 37 a) and the proximal most end of the cable 90 and is attached thereto by a number of methods, including but not limited to, laser welding, soldering or crimping. The hypotube 92 thereby forms a coupler for joining the core 32 and cable 90 as these components are positioned within the hypotube 92. The hypotube can have a diameter of about 0.010 inches, although other dimensions are contemplated.

The cable 90 in one embodiment has a variable stiffness such that the proximal portion 94 is stiffer, e.g., has a tighter braid, than a distal portion 96 to increase the flexibility of the distal portion 96. In other embodiments, the cable 90 is of uniform stiffness. The cable 90 can be of substantially uniform diameter. Various covering materials, e.g., coating, jackets and/or shrink wraps, can be used as an alternative or in addition to vary the stiffness of the cable 90.

A torque tube 97 is positioned over the cable 90. The torque tube 97 extends from a tapered region of the core 32, terminating at the distal coil 91. The torque tube 97 can be soldered at (proximal) end 97 a to the core 32 and at distal end 97 b to the cable 90. The torque tube 97 can also be attached, e.g., soldered or laser welded, to a proximal end of the coil.

A polymer coating(s) and/or jacket(s) can be placed over the torque tube 97 to cover the interstices in the cable 90 and provide a smooth surface. In one embodiment, a PTFE shrink wrap tubing 98 is placed over the torque tube 97 and over a portion of the core 32, preferably extending over the tapered transition region 38 of core 32 to terminate at a proximal end adjacent the uniform diameter region of the core 32. At a distal end, the shrink wrap 98 terminates at the end where the torque tube 97 terminates.

Coiled tip 91 is positioned over a distal portion of the cable 90, and preferably over the distal tip. The coil tip 91 in one embodiment is composed of a soft and malleable material such as platinum and has a uniform pitch and diameter. The distalmost tip of the cable 90 can have a laser welded ball to which the coil 91 is welded to enhance retention of the coil 91 and cable 90. The coiled tip region has a substantially sinuous configuration. In an alternate embodiment, the coiled tip region has a J-tip configuration, as shown for example in FIG. 4B. The coiled tip region can alternatively have a substantially linear configuration in the deployed/uncovered position. In each of these embodiments, preferably a covering such as a jacket, shrink wrap or coating covers the coil 91. In a preferred embodiment, a polyamide such as a nylon or Pebax covering 99 is heat fused over the coil 91, to melt into the interstices. In some embodiments, a heat shrink tubing 99 a, such as FEP, is placed over the heat fused nylon coating. The covering 99, and heat shrink tubing 99 a, terminate adjacent a distal end of the torque tube 97 and adjacent a distal end of the shrink wrap 98.

By way of example only, the components of wire 30 can have the approximate dimensions set forth in the table below. It should be understood that these dimensions are being provided by way of example as other dimensions are also contemplated. These are also approximate values.

APPROXIMATE OUTER APPROXIMATE COMPONENT DIAMETER LENGTH Core 32 .016 inches 139.5 cm (proximal non tapered portion) Core tapered portion .016 inches to .0095 inches  4.35 inches Distal coil 91 .016 inches  3.0 inches Torque tube 97 .013 inches  8.0 inches Shrink tube 98 .014 inches 10.35 inches Cable 90 .010 inches  8.2 inches

The covering material, e.g. coating, jackets, and or shrink wraps, helps to prevent bending or knotting of the wire which could otherwise occur in native vessels. The covering also increases the torsional strength of the wire and also strengthens the wire to accommodate spasms occurring in the vessel. The coating also blocks the interstices of the coil 91 to provide a less abrasive surface. The various coating and/or jackets and/or shrink wrap can be made of PET, Teflon, Pebax, polyurethane or other polymeric materials. The material helps to prevent the native vessel from being caught in the coil 90 and reduces vessel spasms.

The use of the thrombectomy apparatus 10 will now be described. The use, by way of example, is shown and described with respect to the embodiment of FIG. 1 with the sinuous tip of FIG. 4, it being understood that the wire embodiment of FIG. 4B would be utilized in a similar manner. It is also shown for use in the cerebral arteries but use in other vessels is also contemplated.

An access sheath (not shown) is inserted into the vessel and then a guidewire, e.g. 0.035 or 0.038 inches in diameter, and a guide catheter 150 are inserted through the sheath and advanced through the vasculature. The guidewire is removed and a smaller diameter guidewire G, e.g. 0.014 inch diameter, and the introducer catheter 100, are inserted through the guide catheter 150 and access sheath with the guidewire G in the femoral artery F and located via imaging. The introducer catheter 100 is advanced to the desired site through the vascular system into the cerebral arteries A, for example through the Circle of Willis C (see FIGS. 6, 7 and 8). Once at the site, the guidewire G is withdrawn as shown in FIG. 9. Note the introducer catheter 100 is preferably inserted with the RHV 40 attached. That is, the tubular portion 46 of the RHV 40 is inserted through the introducer catheter 100 (see FIG. 10) and attached thereto by rotation of cap 51 as shown in FIG. 9A. In the alternate embodiment of FIGS. 10C and 10D, RHV 40 is attached to thread 124 of the winged luer fitting of introducer catheter 120 by rotation of cap 51 and/or winged handle 122. Note in an alternate embodiment, instead of the RHV 40 attached prior to introduction of the introducer catheter 100 through the guide catheter 150, it can be attached after introduction of catheter 100 through guide catheter 150.

The introducer sheath 60 is inserted through the RHV 40, and attached to the RHV 40 by rotation of cap 58 as shown in FIG. 10A. The thrombectomy wire 30 is inserted through the lumen of the introducer sheath 60, through the lumen of the RHV 40 and into the lumen of the introducer catheter 100. The introducer catheter 100 extends from the guide catheter 150 as shown in FIG. 10, but the wire 30 remains inside the introducer catheter 100. The distal end of the wire 30 is then exposed from the introducer catheter 100 at the target surgical site by relative movement of the wire 30 and introducer sheath 100. Note the wire 30 can be attached to the motor drive shaft 15 at this point or can be attached before exposed or at any other time in the procedure such as prior to insertion of the wire 30 through the introducer sheath 60. Attachment is achieved by connection of the connector tube 80 to the introducer sheath 60 (see FIG. 10B) and attachment of the proximal end of the connector 80 to the motor housing 12 or by other methods, such as a magnetic coupling as described above. The wire 30 extends through the connector tube and attachment of the wire 30 (which extends through connector 80) to the motor drive shaft 15. As noted above, alternatively, the connector tube 80 can be connected to the introducer sheath 60 prior to attachment to the motor housing 12, or alternatively connected after the wire 30 is at the surgical site and exposed from the introducers sheath. The alternate embodiments described herein for coupling the wire to the motor shaft could also be utilized.

With the wire 30 exposed from the introducer catheter 100, switch 19 on housing 12 is actuated to turn on the motor thereby causing wire 30 to rotate about its longitudinal axis to break up/macerate thrombus.

The macerated particles can be removed by suction through side arm 56 of RHV 40 as the particles travel in the space between wire 30 and introducer catheter 100 and RHV 40. The introducer catheter 100 can optionally have a side port(s) and/or the guide catheter 150 can optionally have a side port(s) such as side port 152 for aspirating the small macerated particles in addition to or alternative to side arm 56 of RHV 40.

The delivery sheath can include a balloon to block blood flow and allow aspiration in the blocked space.

While the above description contains many specifics, those specifics should not be construed as limitations on the scope of the disclosure, but merely as exemplifications of preferred embodiments thereof. Those skilled in the art will envision many other possible variations that are within the scope and spirit of the disclosure as defined by the claims appended hereto. 

1. An assembly for breaking up vascular thrombus or other obstructive material, the assembly comprising: a motor housing having a motor contained therein; a motor shaft extending from the motor; a first housing positioned at a distal end of the motor shaft, the first housing having a first magnet positioned therein and recessed from a distal edge of the first housing, the distal edge of the first housing having a first plurality of teeth; a rotational thrombectomy wire; and a second housing positioned at a proximal end of the thrombectomy wire, the second housing having a second magnet positioned therein and recessed from a proximal edge of the second housing, the proximal edge having a second plurality of teeth intermeshing with the first plurality of teeth when the thrombectomy wire is coupled to the motor shaft, the first and second magnets providing an attractive force between the first and second housings to intermesh the first plurality of teeth and the second plurality teeth so rotation of the first housing rotates the second housing, the first and second plurality of teeth slipping when a torque of the motor shaft exceeds a predetermined value.
 2. The assembly of claim 1, wherein a distal end of the thrombectomy wire is non-linear in configuration.
 3. The assembly of claim 2, wherein the non-linear distal end of the thrombectomy wire is J-shaped in configuration.
 4. The assembly of claim 2, wherein the non-linear distal end of the thrombectomy wire is sinuous shaped.
 5. The assembly of claim 1, wherein the assembly includes an introducer sheath having a lumen and the thrombectomy wire is slidable within the lumen.
 6. The assembly of claim 1, wherein the first and second housings are removably coupled.
 7. The assembly of claim 1, wherein the first housing includes a first gap and the second housing includes a second gap, the first magnet movable axially within the first gap as the first housing rotates and the second magnet movable axially in the second gap as the second housing rotates.
 8. The assembly of claim 7, wherein a first plug closes the first gap and a second plug closes the second gap.
 9. The assembly of claim 1, wherein the distal edge of the first housing forms a wavy pattern and the proximal edge of the second housing forms a wavy pattern.
 10. The assembly of claim 8, wherein the thrombectomy wire is mounted in the second plug.
 11. An assembly for breaking up vascular thrombus or other obstructive material, the assembly comprising: a motor housing having a motor contained therein; a motor shaft extending from the motor; a first housing positioned at a distal end of the motor shaft, the first housing having a first magnet positioned therein; a rotational thrombectomy wire; a second housing positioned at a proximal end of the thrombectomy wire, the second housing having a second magnet positioned therein, the first and second magnets providing an attractive force for the first and second housings; and a cover forming a clutch positioned over an edge of one of the first and second housings.
 12. The assembly of claim 11, wherein the first magnet flares a distal end of the housing when inserted therein to provide frictional engagement.
 13. The assembly of claim 11, wherein the cover is in the form of a disc, the disc formed of a polymeric material.
 14. The assembly of claim 13, wherein the disc is a latex sheet of material.
 15. The assembly of claim 11, wherein the cover comprises a polymeric sheet of material positioned between the first and second magnets.
 16. The assembly of claim 11, further comprising a sheath, wherein exposure of the thrombectomy wire from the sheath enables a distal portion of the thrombectomy wire to assume a non-linear configuration.
 17. The assembly of claim 11, wherein the cover is composed of a material that wears away after a period of use. 